CRACK INITIATION AND PROPAGATION BEHAVIOUR OF A HEAT-TREATED CARBON STEEL IN CORROSION FATIGUE

Abstract— When estimating fatigue damage quantitatively it is important to clarify its physical basis. In this study, rotating bending fatigue tests of a heat-treated 0.45% carbon steel were carried out in 3% NaCl solution, in order to clarify the physical basis of corrosion fatigue damage from successive observations of plastic replicas. The results show that corrosion pits are generated during the early stages of cycling, then most of them grow with further cycling until a crack is initiated from each corrosion pit. The initiation of corrosion pits from slip bands is observed only in the case when the stress range is relatively large, and in the range of stress for which slip bands are produced in air. After initiation of a crack, the crack propagates by frequent interactions and coalescence with other cracks. The growth rate of an especially small crack in NaCl solution is larger than that in air. However, the growth rate of a comparatively large crack is smaller in NaCl solution than in air.     

ELEVATED TEMPERATURE FATIGUE CRACK PROPAGATION IN HOT WORK TOOL STEEL

Cyclic tests have been carried out on a hot work tool steel (H13) over a range of temperatures using different waveforms. At a temperature of 125°C, a slow-fast wave resulted in lower crack propagation rates than those with a balanced (or symmetrical) waveform. However, at 500°C normal fatigue crack propagation behaviour was observed in which the slow-fast wave was more damaging than a balanced waveform at the same frequency. Dynamic strain aging is attributed to the reversed crack propagation effect at 125°C.     

THE ROLE OF PRIOR AUSTENITE GRAINS IN FATIGUE CRACK INITIATION AND PROPAGATION IN LOW CARBON MARTENSITE

Abstract— A study has been made of the role of Prior Austenite Grains (PAG) in fatigue crack initiation and propagation in low carbon martensite. The occurrence of ferrite precipitation along prior austenite grain boundaries during rapid cooling will lead to the formation of intergranular cracking. This intergranular cracking has a close relationship with the reduction of the endurance limit for fine grained low carbon martensite.     

SCATTER IN SMALL CRACK PROPAGATION AND FATIGUE BEHAVIOUR IN CARBON STEELS

In order to investigate the physical basis of scatter in fatigue behaviour, rotatory bending of smooth fatigue specimens was carried out using two steels with different microstructures (ferrite/pearlite and tempered martensite). Fifteen or sixteen specimens were fatigued at each stress, and the initiation and propagation behaviour of a crack which led to the final fracture were examined for all the specimens. The emphasis was to investigate the scatter characteristics of fatigue behaviour based on the scatter of small crack propagation data. The data were analysed by assuming the Weibull distribution, and a statistical investigation of the physical basis of scatter was performed, i.e. the distributions for fatigue life, crack propagation life and growth rate of small cracks were established and the relation between the scatter in those distributions was studied.     

FATIGUE CRACK PROPAGATION IN AUSTENITIC STAINLESS STEEL UNDER LOW FREQUENCY LOADING AND SALT WATER CONDITIONS

Fatigue crack growth rates (FCGR) for a steel similar to AISI 316LN have been evaluated in air and salt water. At free corrosion potential, a short crack effect appeared for crack lengths shorter than 4  mm. For longer cracks, a segment (called region I) of the corrosion FCGR curve can be described by an equation with the same coefficients as for steels of ordinary resistance to corrosion. Thus, the process controlling crack propagation is presumably the same for both steels. Corrosion FCGR in region II (range of longer crack lengths and higher Δ K values, where the curve cannot be described by the previously mentioned equation) are slower than for ordinary steels. The plateau in FCGR observed at a cathodic potential corresponds to the higher plateau at the free corrosion potential. An interpretation is presented for the shape of the corrosion FCGR curves at both potentials.     

SHORT FATIGUE CRACK GROWTH BEHAVIOUR OF A LOW CARBON STEEL UNDER CORROSION FATIGUE CONDITIONS

The effect of an aqueous chloride environment upon the development and growth of short fatigue cracks from smooth specimen surfaces has been studied under fully reversed torsional fatigue loading conditions. Crack initiation and growth has been monitored using a plastic replication technique enabling a full history of cracking characteristics to be recorded. Corrosion fatigue conditions were achieved by complete immersion in a 0.6 M NaCl solution, of nominal pH value 6.0, with specimens corroding at the free corrosion potential. Variations to these conditions were obtained by the addition of concentrated hydrochloric acid enabling test solution pH values to be altered, typically pH values of 3.5 and 2.0 were obtained. Further information regarding the effects of the environment on the early stages of crack development were obtained by conducting two stage alternate immersion type testing conditions. Evaluation of these effects through previously established Elastic-Plastic Fracture Mechanics models shows that the environment plays a major role during the early stages of microstructure-dominated crack growth particularly as cracks approach major barriers to propagation and at decreasing levels of applied shear stress.     

CRACK GROWTH BEHAVIOUR OF FATIGUE MICROCRACKS IN LOW CARBON STEELS

The behaviour of low carbon steels has been studied, in particular the initiation and growth of the major crack which led to final fracture of smooth specimens, via surface replica and photomicrograph techniques. From this study, the fracture process and fatigue life prediction characterized by the growth of surface microcracks have been analysed by a new approach unifying the conventional approaches based on the final fracture of materials with the fracture mechanics approach. Knowledge of fracture parameters is critical for non-destructive inspection during service life and the application of fracture mechanics to life prediction and assessment.     

FATIGUE MICROCRACKS IN A LOW CARBON STEEL

Abstract— The behaviour of a low carbon steel has been studied, in particular the initiation, growth and coalescence of fatigue microcracks on the surfaces of smooth specimens via surface replicas and photomicrographs. From the study, quantitative information on the initiation period, growth and coalescence of cracks, statistical distributions of crack length and crack depth, density of cracks, distribution pattern and characteristics of the major crack, were obtained. Knowledge of these parameters is critical for non-destructive inspection during service life and the application of fracture mechanics to life assessment.     

SMALL FATIGUE CRACK GROWTH IN A LOW CARBON STEEL UNDER TENSION–COMPRESSION AND PULSATING-TENSION LOADING

The growth behaviour of small fatigue cracks has been investigated in a low carbon steel under axial loading at the stress ratios R of –1 (tension-compression) and 0 (pulsating-tension). Crack closure was measured to evaluate the effects of stress ratio and stress level on small crack growth. Except for the accelerated growth at stress levels close to the yield stress of the material, at R=–1 small cracks grow faster than large cracks below a certain crack length, but at R= 0 the crack growth rates for small cracks are coincident with those for large cracks in the whole region of crack length investigated. The critical crack length, 2c_c, above which the growth behaviour of small cracks is similar to that of large cracks depends on stress ratio, being 1–2 mm at R=–1 and smaller than 0.7 mm at R=0. The 2c_c value at R=–1 agrees with that obtained under rotating bending (R=–1). The small crack data are closely correlated with large crack growth rates in terms of the effective stress intensity range, ΔK_eff; thus ΔK_eff is found to be a characterizing parameter for small crack growth including the growth at the higher stress levels.     

FATIGUE CRACK INITIATION AND PROPAGATION IN A LOW-CARBON STEEL OF TWO DIFFERENT GRAIN SIZES

Rotary bending fatigue tests were carried out using both plain and notched specimens of a low-carbon steel with two different grain sizes (15 and 50 μm). The process of early crack development was observed by the replication method. The effect of grain size on crack development was studied. The main conclusions were as follows. (1) Fatigue resistance, in terms of the relative positions of the S-N curves, increases with decreasing grain size. This phenomenon is related to the number of cycles to propagate a crack to failure and the condition for the non-propagation of a fatigue crack. (2) The size of a non-propagating crack, which initiates below the fatigue limit, tends to become larger as grain size increases. (3) The difference in fatigue behaviour between small (15μm) and large (50μm) grain sized specimens is due both to a decrease in crack propagation rate and a smaller non-propagating crack limit in the finer grained material.     

A STUDY OF SHORT CRACK GROWTH IN TORSIONAL LOW CYCLE FATIGUE FOR A MEDIUM CARBON STEEL

A study of short crack growth for a medium carbon steel in low cycle torsional fatigue has been carried out in order to measure crack length and derive growth laws. Comparison with a previous analysis of uniaxial tests in low cycle fatigue for the same material provides a tentative basis for formulating an equivalent stress approach to describe uniquely the propagation of short cracks under multiaxial stress.     

A COMPARISON OF NEAR-THRESHOLD FATIGUE CRACK PROPAGATION IN TWO HIGH STRENGTH STEELS

Abstract— Fatigue crack growth rate data for long and short cracks were obtained from two high strength steels used in the aerospace industry. Differences in the behaviour of the two cracks were noted and explained in terms of the three-dimensional nature of short cracks compared to two-dimensional long cracks, the interaction between cracks, the applicability of Linear Elastic Fracture Mechanics (LEFM) and their effect of crack closure.     

SURFACE AND IN-DEPTH CRACK PROPAGATION IN HIGH TEMPERATURE LOW-CYCLE FATIGUE OF SUS 316 STAINLESS STEEL

Abstract— The low-cycle fatigue crack propagation behaviour of surface cracks in SUS316 stainless steel at 700°C, in both the surface direction and the in-depth direction, has been studied with special emphasis on the role of oxidation. The coalescence behaviour of surface cracks is essential for the process of crack propagation in high temperature low cycle fatigue, irrespective of the existence of oxidation effects. For sub-surface cracks the process of crack propagation is divided into two stages characterized by differences in fracture mode. In both stages, the in-depth crack propagation rate in air is higher than that in vacuum. This difference in crack propagation rate is the main reason for the decrease of fatigue life in air compared with that in vacuum. The crack propagation behaviour in the in-depth direction can be estimated from the conversion of the surface crack length into the subsurface depth by the use of an aspect ratio.     

SHORT CRACK FATIGUE BEHAVIOUR IN A MEDIUM CARBON STEEL

The initiation stage and short crack behaviour in torsional fatigue of a 0.4% C steel was investigated by a replication technique. The fatigue cracks initiated and propagated in the ferrite phase which is located at the prior austenite grain boundaries in the form of long allotriomorphs. At this stage of crack development it is proposed that crack growth rate depends on the extent and intensity of plasticity at the tip of the crack. Crack growth per cycle is correspondingly proportional to the strength of the slip band. The ferrite-pearlite boundaries are strong barriers to crack propagation, which is manifested by a deceleration of growth and possible arrest. On raising the stress level the previously non-propagating cracks may continue to grow by branching or joining with other cracks in the ferrite phase. This process is repeated until the stress fields of one or more dominant cracks attain a critical value to sustain continued growth that leads to failure.     

ON THE OVERLOAD INDUCED FATIGUE CRACK PROPAGATION BEHAVIOR IN ALUMINUM AND STEEL ALLOYS

The overload induced fatigue crack propagation behavior of several aluminum and steel alloys was examined as a function of the baseline stress intensity factor range (δ K _b). In order to gain a clearer understanding of the parameters which influence the cyclic delay phenomenon, under both plane strain and plane stress conditions, tests were conducted at δ K _b values ranging from the near threshold regime to high δ K levels approaching fast fracture. Large amounts of overload induced cyclic delay (˜100,000 cycles) were observed at both high and low δ K levels (provided the plastic zone size/thickness ratio and plastic zone size/grain size ratio approached unity, respectively) with significantly less delay occurring at intermediate δ K values. All alloys examined exhibited this type of delay behavior which can be described by a "U-shaped" plot. The delay phenomenon at high δ K _b levels under plane stress conditions was attributed to increased crack closure associated with large tensile displacements in the wake of the advancing crack. At low δ K _b levels increasing cyclic delay was attributed to an increased effective overload ratio as δ K approached δ K _th.     

CRACK CLOSURE AND PLASTIC ZONE SIZES IN FATIGUE

Abstract— An elastic-plastic finite element simulation of growing fatigue cracks which accounts for plasticity-induced crack closure is used to study the size of the forward and reversed plastic zones at the crack tip. Forward plastic zone widths for fatigue cracks and stationary, monotonically loaded cracks are compared and found to be similar. The width of the forward plastic zone at the tip of a fatigue crack is not significantly influenced by closure. The traditional Irwin-Rice estimate for crack tip plastic zone size in plane stress is found to be generally consistent with the finite element results. The width of the reversed plastic zone at the tip of a growing fatigue crack in plane stress is found to be considerably less than one-fourth the size of the forward plastic zone, the traditional Rice estimate. This decrease appears to be due to fatigue crack closure. A simple model is developed which permits estimation of the reversed plastic zone size for any stress ratio from information about maximum and minimum stresses and the closure stress. The predictions of this model agree closely with plastic zone sizes calculated by the finite element analysis. These observations appear to be consistent with experimental measurements of forward and reversed plastic zones sizes reported in the literature.     

EFFECT OF LASER BEAM RADIATION ON FATIGUE CRACK PROPAGATION IN AISI 4150 STEEL

The effect of laser beam radiation on fatigue crack growth in AISI 4150 steel was performed on compact-tension (CT) specimens, in which a composite region (CR) comprised of the hardened zones (HZs) on the top and bottom surfaces and the base metal (BM) in the interior, was aligned either along or normal to the crack growth direction. The microstructure of the HZs consisted of martensite, while lower bainite was present in the 300 °C preheated laser-hardened specimens. When the crack propagated along the laser tracks (LTs), the fatigue crack growth rates (FCGRs) of the laser-hardened specimen were lower than those of the base plate, particularly at low ΔK ranges. On the other hand, for a crack propagating normally to the LTs, decelerated FCGRs in the regions preceding the CR and accelerated FCGRs within the CR itself were found. However, enhanced FCGRs in the CR were not found in preheated specimens with a bainite structure in the HZs as the crack grew normal to the LTs. The enhancement of FCGRs in the CR, which became more accentuated at high ΔK values, was closely related to an embrittled microstructure (martensite) in the HZs.     

UNSTABLE FATIGUE CRACK PROPAGATION AND FATIGUE FRACTURE TOUGHNESS OF STEELS

This paper presents the results of fatigue crack growth and fatigue fracture toughness studies of a high-pressure vessel steel with particular emphasis on the influence of heat treatment, low temperatures, plastic prestraining, the stress ratio and specimen dimensions. It has been shown that steels in an embrittled state, caused primarily by thermal treatment and low-temperatures, exhibit unstable fatigue crack growth which is characterized by alternate crack jumps (cleavage zones) and zones of fatigue crack growth. The fatigue fracture toughness, which corresponds to the first crack jump, and final fracture can be appreciably lower (i.e. up to 50%) than the static fracture toughness under plane strain conditions at the corresponding temperature. An analysis has been performed of unstable and stable fatigue crack growth and a model of unstable crack propagation is proposed which accounts for the observed experimental behaviour.